High fatigue strength porous structure

ABSTRACT

A porous apparatus includes a first layer and a second layer. The second layer has a plurality of struts. At least some of the struts define a porous geometry defining a plurality of faces, at least one of the plurality of the faces at least partially confronting the first layer. Each face is bounded by intersecting struts at vertices. Less than all of the vertices of each face of the porous geometry at least partially confronting the first layer are connected by a strut to the first layer. A process of producing the at least partially porous structure includes depositing and scanning metal powder layers. At least some of the scanned metal powder layers form either one or both of a portion of a first section of the structure and a portion of a second section of the structure formed by at least the struts defining the porous geometry.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of the filing date of U.S.Provisional Patent Application No. 62/508,058 filed May 18, 2017, thedisclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates generally to three-dimensional porousstructures and, in particular, to three-dimensional structures withporous surfaces having high fatigue strength and a process for thepreparation of such structures.

BACKGROUND OF THE INVENTION

The field of additive layer manufacturing (ALM) has seen many importantrecent advances in the fabrication of articles directly from computercontrolled databases. These advances have greatly reduced the time andexpense required to fabricate articles, particularly in contrast toconventional machining processes in which a block of material, such asmetal, is machined to engineering drawings.

Additive layer manufacturing has been used to produce various porousstructures including, for example, medical implants. These structuresare built in a layer-by-layer fashion in which individual layers oftenform portions of unit cells that have regular geometric shapes orirregular shapes having varied sides and dimensions. Various methods forproducing a three-dimensional porous tissue ingrowth structure aredisclosed in U.S. Pat. No. 9,180,010 filed Sep. 14, 2012 disclosingconformal manipulation of a porous surface; U.S. Pat. No. 9,456,901filed Jul. 29, 2010 (“the '901 patent”) disclosing methods of creatingporous surfaces having unit cells; and U.S. Pat. No. 7,537,664 filedNov. 7, 2003 disclosing methods of beam overlap; the disclosures of eachof which are incorporated herein by reference.

Advantageously, ALM allows for a solid substrate, e.g., a core of animplant, and an outer porous layer to be manufactured simultaneously,reducing manufacturing steps and materials, and thus costs, compared toconventional machining processes. However, current ALM techniques thatform solid substrates and then porous layers onto the substrates createrough surfaces on the substrates that act as stress risers and result inan overall structure having relatively low fatigue strength. Due totheir low fatigue strength, structures formed in this manner have anincreased risk of fracture during use. Avoiding porous surfaces in highstress regions serves to increase the fatigue strength of suchstructures, but this approach leads to other undesirable properties ofproduced articles, e.g., by reducing available surfaces for bonein-growth in a medical implant which causes suboptimal implant fixationin the body.

Polishing the surfaces of devices is known to increase the fatiguestrength of the devices. One well-known technique for polishing internalsurfaces is abrasive flow machining, a process for polishing internalsurfaces using a pressurized flow of a paste. The abrasive fluid flowsthrough the interstices of the subject device and smooths its roughsurfaces.

Porous layers of solid-porous layer combinations formed by current ALMtechniques have at least one of varying pore shapes and sizes, such asmay be caused by the use of randomization techniques including thosedescribed in the '901 patent, and relatively small pore sizes which mayresult in uneven or insufficient flow, respectively, of abrasive fluidsduring polishing. Such pore formations may lead to preferentialpolishing of a path through the largest pores which may not be along theinterface of the solid and porous volumes, where the best surface finishis needed.

Thus, there is a need for a new process to form highly porous structureswithout sacrificing fatigue strengths.

BRIEF SUMMARY OF THE INVENTION

In accordance with an aspect, a computer-aided design (CAD) first modelbuild structure may include unit cells that may be populated with porousgeometries, each of the porous geometries may be made up of struts thatextend to vertices of the unit cells and collectively define faces andintersect at nodes at the vertices. The porous geometries can be used tocontrol the shape, type, degree, density, and size of porosity withinthe structure. The first model build structure may be subjected toconformal manipulation such that certain nodes lying outside a boundaryare repositioned to lie on the boundary. The first model build structuremay include connection elements, which may be a set of equallyspaced-apart joining struts, extending from the nodes repositioned onthe boundary. The connection elements may connect the first model buildstructure to a mating model build structure, which may be a solid CADmodel build structure.

The porous geometries may include first faces that at least partiallyconfront, i.e., face, the mating model build structure, in which thefirst faces may extend in a direction parallel to a central axis of themating model build structure or the faces may extend in any non-paralleldirection, and each first face is positioned directly in front of andprojects onto the mating building structure. Each of the first faces maybe connected to the mating model build structure by a single connectionelement extending from one of the nodes of the first faces on theboundary. In some arrangements, the first model build structure may beuniformly spaced from the boundary such that connection elements mayhave substantially equal lengths.

A tangible, fabricated porous structure having a solid base or core andcorresponding to a combination of the first and mating model buildstructures may be formed layer by layer using ALM. Notably, thistangible structure would provide for an even flow of abrasive fluidalong the porous-solid interface because of the joining struts of equallength. In this manner, a higher fatigue strength of the tangiblestructure may be achieved.

In accordance with another aspect, a porous apparatus may include afirst layer and a second layer having a plurality of struts. A portionof the plurality of struts may define a porous geometry. The porousgeometry may define a plurality of faces, at least one of the pluralityof faces at least partially confronting the first layer. Each of thefaces may be bounded by intersecting struts at vertices. Less than allof the vertices of each face at least partially confronting the firstlayer may be connected to the first layer by a strut, in which each suchstrut may be a first attachment strut.

In some arrangements, the first and second layers may be made of ametal. The metal preferably may be titanium, titanium alloys, stainlesssteel, cobalt chrome alloys, tantalum and niobium, or any combinationthereof. In some arrangements, the porous geometry may be in the form ofan octahedron, a dodecahedron, or a tetrahedron. In some arrangements,the first layer may be solid.

In some arrangements, additional struts of the plurality of struts maydefine additional porous geometries that each may define additionalfaces at least partially confronting the first layer. Each of theadditional faces may be bounded by intersecting struts at vertices. Lessthan all of the vertices of each of the additional faces at leastpartially confronting the first layer may be connected by additionalattachment struts to the first layer. The first attachment strut and theadditional attachment struts may have the same length. In some sucharrangements, the additional attachment struts may extend in the samedirection. In some such arrangements, the additional attachment strutsmay extend along axes extending through a central axis of the firstlayer.

In accordance with another aspect, a porous apparatus includes a firstlayer and a second layer having a plurality of struts. Some of thestruts define a first porous geometry. The first porous geometry isconnected to the first layer by only a first attachment strut.

In some arrangements, the first and second layers may be made of a metalselected from the group consisting of titanium, titanium alloys,stainless steel, cobalt chrome alloys, tantalum and niobium. In somearrangements, the first porous geometry may be in the form of anoctahedron, a dodecahedron, or a tetrahedron. In some arrangements, thefirst layer may be solid.

In some arrangements, additional struts of the plurality of struts maydefine additional porous geometries each connected to the first layer byonly an additional attachment strut. The first attachment strut and theadditional attachment struts may have the same length. In some sucharrangements, the additional attachment struts may extend in the samedirection. In some such arrangements, the additional attachment strutsmay each extend along an axis extending through a central axis of thefirst layer.

In some arrangements, the porous apparatus may be a medical implant.

In accordance with another aspect, a porous structure may be produced.In producing the porous structure, a first layer of a metal powder maybe deposited onto a substrate. The first layer of the metal powder maybe scanned with a high energy beam to form either one or both of aportion of a first section of the structure and a portion of a pluralityof struts. The struts may define a porous geometry. The struts and theporous geometry may form a second section of the structure. Successivelayers of the metal powder may be deposited onto respective previouslayers of powder. Each of the successive layers of the powder may bescanned with the high energy beam until the first and second sectionsand the portion of the plurality of struts defining the porous geometry.The porous geometry may be attached to the first section by only a firstattachment strut.

In some arrangements, the substrate may be separable from the porousstructure. In some other arrangements, the substrate may be integralwith the porous structure such that the substrate is inseparable fromthe porous structure. In some arrangements, the porous apparatus may bea medical implant.

In some arrangements, the high energy beam may be an electron beam. Insome arrangements, the high energy beam may be a laser beam. In somearrangements, the first section of the structure may be solid. In somearrangements, additional struts may define additional porous geometrieseach attached to the first section by only an additional firstattachment strut. The first attachment strut and the additionalattachment struts may have the same length. In some such arrangements,the additional attachment struts may extend in the same direction. Insome such arrangements, the additional attachment struts may each extendalong an axis extending through a central axis of the structure.

In accordance with another aspect of the invention, a porous structuremay be produced. In producing the porous structure, a first layer of ametal powder may be deposited onto a substrate. The first layer of themetal powder may be scanned with a high energy beam to form either oneor both of a portion of a first section of the structure and a portionof a plurality of struts. The struts may define a porous geometry. Thestruts and the porous geometry may form a second section of thestructure. Successive layers of the metal powder may be deposited ontorespective previous layers of powder. Each of the successive layers ofthe powder may be scanned with the high energy beam until the portion ofthe first section and the portion of the plurality of struts definingthe porous geometry are formed. The porous geometry may define aplurality of faces, at least one of the plurality of the faces at leastpartially confronting the first section of the structure. Each of thefaces may be bounded by intersecting struts at vertices. Less than allof the faces of each face at least partially confronting the firstsection may be connected to the first section of the porous structure bya strut, in which each such strut may be a first attachment strut.

In some arrangements, the substrate may be separable from the porousstructure. In some other arrangements, the substrate may be integralwith the porous structure such that the substrate is inseparable fromthe porous structure. In some arrangements, the porous apparatus may bea medical implant.

In some arrangements, the first and second layers may be made of ametal. The metal preferably may be titanium, titanium alloys, stainlesssteel, cobalt chrome alloys, tantalum and niobium, or any combinationthereof. In some arrangements, the high energy beam may be an electronbeam. In some arrangements, the high energy beam may be a laser beam. Insome arrangements, the first section of the structure may be solid.

In some arrangements, additional struts of the plurality of struts maydefine additional porous geometries that each may define additionalfaces at least partially confronting the first layer. Each of theadditional faces may be bounded by intersecting struts at vertices. Lessthan all of the vertices of each of the additional faces at leastpartially confronting the first layer may be connected by additionalattachment struts to the first layer. The first attachment strut and theadditional attachment struts may have the same length. In some sucharrangements, the additional attachment struts may extend in the samedirection. In some such arrangements, the additional attachment strutsmay each extend along an axis extending through a central axis of thefirst layer.

In accordance with another aspect of the invention, a computer-generatedmodel of a three-dimensional structure constructed of porous geometriesmay be prepared according to a process. In this process, acomputer-generated component file including a porous CAD volume having aboundary may be prepared. A space may be populated by a processor. Thespace may include the porous CAD volume which may be populated by unitcells. The unit cells with porous geometries may be populated by aprocessor. A plurality of porous geometries may have a plurality ofstruts with nodes at each of the ends of the struts which may include afirst strut overlapping the boundary. The first strut may have a length,a first node outside the porous CAD volume, and a second node inside theporous CAD volume. All struts entirely outside the porous CAD volume maybe removed such that each of the remaining struts is connected at itscorresponding node. The space may be populated, by a processor, with asecond strut extending beyond the boundary from a node for connectionwith a mating structure.

In some arrangements, the node from which the second strut extendsbeyond the boundary may define an intersection of two struts of a porousgeometry on or confronting the boundary. In some arrangements, duringthe process, the first strut overlapping the boundary may be removed, bya processor, when the first node at the first end of the strut isfurther from the boundary than the second node at the second end of thefirst strut.

In some arrangements, the second node at the second end of the firststrut may be connected to an adjacent strut inside the porous CADvolume. A closer of the first and the second nodes may be moved to aposition along the boundary during the process. When the first node isthe closer node, the length of the first strut may be changed such thatthe first strut remains connected to the first node. When the secondnode is the closer node, the length of the adjacent strut may be changedsuch that the first strut remains connected to the second node. When thesecond node is the closer node, the first node and the first strutoverlapping the boundary may be removed.

In some arrangements, the second strut may be connected with the matingstructure. In some arrangements, the mating structure may correspond toa solid or substantially solid structure. In some arrangements, a methodof fabricating a porous structure may include three-dimensional (3-D)printing a three-dimensional structure having a shape and dimensionscorresponding to the computer-generated model prepared.

In accordance with another aspect of the invention, a non-transitorycomputer-readable storage medium may have computer readable instructionsof a program stored on the medium. The instructions, when executed by aprocessor, may cause the processor to perform a process of preparingcomputer-generated model of a three-dimensional structure constructed ofporous geometries. In this process, a computer-generated component fileincluding a porous CAD volume having a boundary may be prepared. A spaceincluding the porous CAD volume with unit cells may be populated by aprocessor. The unit cells may be populated, by a processor, with theporous geometries. A plurality of the porous geometries may have aplurality of struts that may have opposing ends. Each of the ends may beconnected at a corresponding node. A first strut of the plurality ofstruts may overlap the boundary. The first strut may have a length, afirst node at a first end outside the porous CAD volume, and a secondnode at a second end inside the porous CAD volume. All struts entirelyoutside the porous CAD volume may be removed, by a processor, such thateach end of the remaining struts remains connected at its correspondingnode. The space may be populated, by a processor, with a second strutextending beyond the boundary from a node for connection with a matingstructure.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the subject matter of the presentinvention and the various advantages thereof may be realized byreference to the following detailed description, in which reference ismade to the following accompanying drawings:

FIG. 1 is a functional diagram of a system in accordance with anexemplary embodiment;

FIG. 2A illustrates a wireframe of porous geometries created within unitcells that intersect a boundary of a porous CAD volume, which models theporous portion of the structure to be manufactured up to the outerboundary of the porous portion, as known in the prior art;

FIG. 2B illustrates the nodes and the struts of the porous geometrieswithin the unit cells of FIG. 2A;

FIGS. 3A and 3B illustrate the wireframe of the porous geometries ofFIG. 2 after removing the full length of struts lying entirely outsidethe boundary of the porous CAD volume and removing the full length ofstruts overlapping the boundary that have outer nodes further from theboundary than their corresponding inner nodes as known in the prior art;

FIGS. 4A and 4B illustrate the wireframe of the porous geometries ofFIG. 3 after repositioning of the nodes closest to the boundary topositions along the boundary of the porous CAD volume through conformalmanipulation, as known in the prior art;

FIGS. 5A and 5B are plan and side cross-sectional views of a solid CADvolume surrounded by a porous CAD volume of a cylindrical geometry, inaccordance with an embodiment;

FIG. 6 is a partial cross-sectional side view of a porous CAD volumealong an edge of a solid CAD volume aligned along a Z-axis, inaccordance with another embodiment;

FIG. 7 is a partial cross-sectional side view of a porous CAD volumealong an edge of a solid CAD volume aligned along a Z-axis in accordancewith another embodiment; and

FIG. 8 is a process flow diagram in accordance with an embodiment.

DETAILED DESCRIPTION

FIG. 1 depicts system 105 that may be used to generate, store and sharethree-dimensional models of structures. System 105 may include at leastone server computer 110, first client computer 120, and in someexamples, second client computer 130. These computers may send andreceive information via network 140. For example, a first user maygenerate a model on first client computer 120 which may be uploaded toserver 110 and distributed via network 140 to second client computer 130for viewing and modification by a second user.

Network 140, and intervening communication points, may comprise variousconfigurations and protocols including the Internet, World Wide Web,intranets, virtual private networks, wide area networks, local networks,private networks using communication protocols proprietary to one ormore companies, Ethernet, WiFi, and HTTP, and various combinations ofthe foregoing. Such communication may be facilitated by any devicecapable of transmitting data to and from other computers, such as modems(e.g., dial-up, cable or fiber optic) and wireless interfaces. Althoughonly a few devices are depicted, a conventional system may include alarge number of connected computers, with each computer being at adifferent communication point of the network.

Each of computers 110, 120, and 130 may include a processor and memory.For example, server 110 may include memory 114 which stores informationaccessible by processor 112, computer 120 may include memory 124 whichstores information accessible by processor 122, and computer 130 mayinclude memory 134 which stores information accessible by processor 132.

Processors 112, 122, 132 may be any conventional processor, such ascommercially available CPUs. Alternatively, the processors may bededicated controllers such as an ASIC, FPGA, or other hardware-basedprocessor. Although shown in FIG. 1 as being within the same block, theprocessor and memory may comprise multiple processors and memories thatmay or may not be stored within the same physical housing. For example,memories may be a hard drive or other storage media located in a serverfarm of a network data center. Accordingly, references to a processor,memory, or computer will be understood to include references to acollection of processors, memories, or computers that may or may notoperate in parallel.

The memories may include a first part storing applications orinstructions 116, 126, 136 that may be executed by the respectiveprocessor. Instructions 116, 126, 136 may be any set of instructions tobe executed directly (such as machine code) or indirectly (such asscripts) by the processor. In that regard, the terms “applications,”“instructions,” “steps” and “programs” may be used interchangeablyherein.

The memories may also include a second part storing data 118, 128, 138that may be retrieved, stored or modified in accordance with therespective instructions. The memory may include any type capable ofstoring information accessible by the processor, such as hard-drive,memory card, ROM, RAM, DVD, CD-ROM, write-capable, and read-onlymemories or various combinations of the foregoing, where applications116 and data 118 are stored on the same or different types of media.

In addition to a processor, memory and instructions, client computers120, 130 may have all of the components used in connection with apersonal computer. For example, client computers 120, 130 may includerespective electronic displays 129, 139 (e.g. a monitor having a screen,a touch screen, a projector, a television, a computer printer, or anyother electrical device that is operable to display information), one ormore user inputs (e.g. a mouse, keyboard, touch screen and/ormicrophone), speakers, and all of the components used for connectingthese elements to one another.

Instructions 126, 136 of first and second client computers 120, 130 mayinclude building applications 125, 135. For example, the buildingapplications may be used by a user to create three-dimensionalstructures, described further herein. The building applications may beassociated with a graphical user interface for displaying on a clientcomputer in order to allow the user to utilize the functions of thebuilding applications.

A building application may be a CAD three-dimensional modeling programor equivalent as known in the art. Available CAD programs capable ofgenerating such a structure include Autodesk® AutoCAD®, Creo® byParametric Technology Corporation (formerly Pro/Engineer), Siemens PLMSoftware NX™ (formerly Unigraphics), and CATIA® by Dassault Systemes.

Data 118, 128, 138 need not be limited by any particular data structure.For example, such data may be stored in computer registers, in arelational database as a table having a plurality of different fieldsand records, or XML documents. The data may also be formatted into anycomputer-readable format, which preferably may be binary values, ASCIIor Unicode. Further, the data may comprise any information sufficient toidentify the relevant information, such as numbers, descriptive text,proprietary codes, pointers, references to data stored in other memories(including other network locations) or information that is used by afunction to calculate the relevant data. For example, data 128 of firstclient computer 120 may include information used by building application125 to create three-dimensional models.

In addition to the operations described above and illustrated in thefigures, various other operations will now be described. It should beunderstood that the following operations do not have to be performed inthe exact order described below. Instead, various steps may be handledin a different order or simultaneously. Steps may also be omitted oradded unless otherwise stated herein.

An overall three-dimensional representation of a component may first begenerated by preparing a CAD model. This overall CAD model may includeone or more distinct CAD volumes, e.g., solid and porous CAD volumes,that are intended to be modeled by a model build structure which in turnused to manufacture a part as either solid or porous geometries or acombination of the two.

Solid CAD volumes may be sliced into layers of a predetermined thicknessready for hatching, re-merging with the porous volume (post-latticegeneration) and subsequent manufacture.

Porous CAD volumes (the basic principles of which are detailed in FIGS.2A and 2B) may be processed using bespoke software. In some examples, amodel structure, such as model build structure 50 identified in FIGS. 3Aand 3B is made up of a plurality of struts defining individual porousgeometries which are organized within tessellated unit cells, e.g.,porous geometries 55 identified in FIG. 2A which are organized withintessellated unit cells 60. Many designs of porous geometries arepossible to impart various strength, surface, and/or othercharacteristics into the porous CAD volume. For example, these porousgeometries can be used to control the shape, type, degree, density, andsize of porosity within the structure. Such porous geometry designs maybe bounded by unit cells that may be dodecahedral, octahedral,tetrahedral (diamond), as well as many other various shapes. Besidessuch regular geometric shapes, the cells of the present invention may beconfigured to have irregular shapes where various sides and dimensionshave little if any repeating sequences. The cells, including the unitcells, may be configured to constructs that closely mimic the structureof trabecular bone, for instance. Porous geometries can be spacefilling, in which all the space within a three-dimensional object isfilled with porous geometries but do not always fill the space of anobject they are used to produce.

The first step in creating a porous CAD volume is to calculate abounding box, i.e., a box with x, y, and z dimensions corresponding to,or slightly larger than, a predefined boundary of the porous CAD volume,which may be the entire boundary or a portion of a boundary. Thebounding box is then divided into a number of cells, such as unit cells60, defined by x, y, and z dimensions. Calculations are then performedduring an interrogation on each individual cell 60 to ascertain if eachcell is within or intersects the boundary of the porous CAD volume. Ifthese conditions are satisfied for an individual cell, that cell isretained such as in the example of FIG. 2A, and if they are notsatisfied, that cell is discarded. Once all cells have beeninterrogated, the overall porous geometry is populated within cells thathave been retained, such as in the example of FIGS. 2A and 2B in which acollection of porous geometries 55, which together form model buildstructure 50, are populated within unit cells 60 that have been retainedin a porous CAD volume.

Each of the individual porous geometries 55 is made up of struts, i.e.,segments having a length. Nearly all of the struts meet at a node orintersection. The position of the nodes may be identified within anarray of the data of the processor according to Cartesian, polarcoordinates, or other user-defined coordinates.

In one example, a porous CAD volume is bounded by predefined boundary100 that corresponds to the intended surface of a part to be formed. Asshown in FIGS. 2A and 2B, some unit cells along predefined boundary 100have overlapping struts that cross over the boundary. The struts haveinner nodes within boundary 100 and outer nodes outside the boundary. Toproduce a porous structure having struts that terminate at boundary 100,each strut that intersects the boundary is either fully retained orremoved depending on the distance of its nodes from boundary 100. Eachstrut having an outer node farther from boundary 100 than its inner nodeis fully removed. Whereas, each strut having an outer node closer toboundary 100 than its inner node is fully retained. In this example,with reference to FIGS. 2B, 3A, and 3B, struts 9-12, 16 and 19 are fullyremoved because their outer nodes are farther from the boundary thantheir inner nodes. Whereas, struts 8, 13-15, 17-18, and 20-21 are fullyretained because outer nodes 25, 30, 32, 34, and 35, although outsidethe boundary 100, are still closer than their corresponding inner nodes.

Still referring to this example, as shown in FIGS. 4A and 4B, afterremoval of the appropriate struts, the nodes closest to boundary 100,nodes 25-35, may be repositioned to lie on the boundary, and as suchnodes 25-35 are conformal nodes. In some examples, the conformal nodesmay be repositioned based on a mathematical calculation based on theoriginal position of each of these nodes, e.g., the distance from theboundary of each of these nodes, or based on the original length of thestruts attached to these nodes that overlap the boundary, or based onboth of these values. In this way, the shape of the structure may bemaintained or at least substantially maintained when having conformalnodes along the boundary.

Upon repositioning of nodes 25-35, the struts connected to these nodesmay be lengthened or shortened to maintain connectivity with therepositioned nodes. Alternatively, nodes 25-35 may not be repositionedbut rather discarded and replaced by new nodes. Likewise, the strutsoriginally connected to nodes 25-35 may be discarded and replaced by newstruts that are longer or shorter than the original struts to provideconnectivity with the corresponding repositioned nodes. In this manner,the unit cells and nodes experience conformal manipulation.

In another example, only struts having both nodes inside the boundarymay be retained. The node closest to the boundary may then berepositioned to lie on the boundary and any adjacent strut previouslyconnected to the repositioned node may be lengthened or shortened tomaintain connection with the repositioned node, as described above.Alternatively, the nodes and struts may be replaced with new nodes andstruts, as above.

The use of polar or spherical coordinates may be preferred to the use ofCartesian coordinates when a surface of a model build structure to beformed is curvate or cylindrical. In this manner, nodes repositioned ona boundary may be positioned at the same angle defining a replaced nodebut at a different radius from the origin of a polar coordinate systembeing used to create a model build structure. However, otheruser-defined node positioning system also may be used to form a modelbuild structure having nodes along an outer boundary that fit thecontours of the outer boundary of the component being modeled.

Referring now to FIGS. 5A and 5B, porous structure 210, which in somearrangements may be in the form of a medical implant, includes firstlayer or section 220 and porous model build structure 250 that connectsto the first layer at interface 225. First layer 220 forms a base orcore of structure 210 and, as in this example, may be solid, although inalternative arrangements the first layer may be at least partiallyporous. Porous model build structure 250 includes porous layer 230 andjoining struts 240 that connect the model build structure to first layer220 at interface 225. Porous layer 230 includes a plurality of porousgeometries 255.

Porous geometries 255 may be modeled using available CAD programs, whichpreferably may be any of those described previously herein, through theuse of cells in the manner described previously herein. In the exampleshown, octahedral unit cells may be used to form porous geometries 255.In alternative arrangements, other cell designs may be utilized, whichmay, in some arrangements, be either or both octahedral and dodecahedralunit cells. In the example shown, each porous geometry 255 includes aplurality of struts 245 that intersect at vertices defining boundarynodes 270 along circular boundary 200 and at vertices defining nodes 275at positions away from the boundary to define faces 285 of the unitcells facing away from first layer 220 and faces 295 at least partiallyconfronting first layer 220.

Porous geometries 255 along boundary 200 define faces 295 that at leastpartially confront first layer 220 and have struts 245 connected at oneof their ends to boundary nodes 270, which in this example have beenrepositioned onto porous boundary 200 in the same manner as nodes 25-35were repositioned along boundary 100 as described above with respect tomodel build structure 50. Each face 295 at least partially confrontingfirst layer 220 is connected to the first layer by single joining strut240 extending from one of the boundary nodes 270. In this manner, asboundary 200 is equidistant about its circumference from first layer220, boundary nodes 270 are set at substantially equal distances fromfirst layer 220, and as a result, joining struts 240 connecting porouslayer 230 to first layer 220 are all of substantially equal lengths.

With this configuration, abrasive polishing material can flow evenlyalong an interface of a fabricated structure corresponding to interface225 of structure 210 at a junction of a core and a porous section of thefabricated structure corresponding to first layer 220 and porous modelbuild structure 250, respectively. In this manner, a higher fatiguestrength of the fabricated structure corresponding to structure 210 maybe achieved.

Unlike nodes 270, nodes 275 are not connected to any joining strut 240extending to first layer 220. In this manner, less than all of the nodesof each porous geometry 255 are connected to first layer 220.

Although the joining struts may be of substantially equal lengths, suchas in the example of FIGS. 5A and 5B, the joining struts may extend inany possible build direction. In the example of FIGS. 5A and 5B, joiningstruts 240 extend in parallel planes perpendicular to a central axis offirst layer 220 and of structure 210 (shown in dashed lines in FIG. 5B)and in various directions ranging between approximately 0 degrees and360 directions about a circumference of boundary layer 200 and firstlayer 220. Alternatively, joining struts 240 may be defined as beingoriented in directions defined by the intersection of a plane defined bya vector normal to their respective attachment points on the first layer220 and orthogonal to boundary layer 200, which may correspond to abuild surface. As further shown in FIG. 5A, in some such arrangements,joining struts 240 all extend along axes extending through a centralaxis of first layer 220.

Referring to FIGS. 6 and 7, in other examples, the joining struts mayextend in the same direction. As shown in FIG. 6, structure 310 includesjoining struts 340 extending in an upward direction along the z-axis andconnecting first layer 320 to porous layer 330. In contrast, as shown inFIG. 7, structure 410 includes joining struts 440 extending in adownward direction along the z-axis and connecting first layer 420 toporous layer 430. Alternatively, joining struts 340, 440 may be definedas being oriented in directions defined by the intersection of a planeoriented 45 degrees upward or downward from its attachment point onfirst layers 320, 420 towards the boundary nodes along boundaries 300,400, respectively. In another example, adjacent joining struts mayextend in an alternating upward-downward pattern. In this manner,interconnecting pore size may be larger at the interface of the poroussurface and the first layer, which may be a core. The largerinterconnecting pore size may preferably allow a greater amount ofabrasive material to flow along the interface.

In some arrangements, the joining struts, such as joining struts 240,340, 440 may be larger or smaller in diameter than other struts of amodel build structure, such as model build structure 250. In somearrangements, the joining struts, such as joining struts 240, 340, 440may be longer or shorter than other struts of a model build structure,such model build structure 250. In some arrangements, more than a singlejoining strut, such as joining struts 240, 340, 440, may extend fromvertices of intersecting struts defining faces of a porous geometry atleast partially confronting the first layer, e.g., core, of a structure,but in such arrangements, less than all of the vertices of each face ofthe porous geometry at least partially confronting the first layer maybe connected by a strut to the first layer.

Each of structures 210, 310, and 410 may be formed in a layer-by-layerfashion during an ALM, i.e., 3D printing, process using a high energybeam, which may be a selective laser sintering (SLS) or selective lasermelting (SLM) process as described in U.S. Pat. Nos. 7,537,664;8,728,387; and 9,456,901, the disclosures of each of which are herebyincorporated by reference herein. A first layer or portion of a layer ofmetal powder is deposited onto a substrate, which, in some arrangements,may be a core of a structure, a base, or a work platform, and thenscanned with the high energy beam so as to sinter or melt the powder andcreate a portion of a plurality of predetermined porous geometries, suchas porous geometries 255, 355, 455. Successive layers of the metalpowder are then deposited onto previous layers of the metal powder andalso respectively scanned with the high energy beam prior to thedeposition of subsequent layers of the metal powder. The scanning anddepositing of successive layers of the metal powder continues thebuilding process of the predetermined porous geometries. Suchcontinuation of the building process refers not only to a continuationof a predetermined porous geometry from a previous layer but also abeginning of a new predetermined porous geometry as well as or insteadof the completion of a predetermined porous geometry, depending on thedesired characteristics of the structure to be fabricated.

The structures formed using this process may be partially porous and, ifdesired, have interconnecting pores to provide an interconnectingporosity. The base or core may be fused to the 3D-printed structure,which may be a porous layer or section of the fabricated structure. Atleast one of the base or core and the 3D-printed structure preferablymay be made of any of cobalt chrome alloy, titanium or alloy, stainlesssteel, niobium and tantalum. Thus, a mixture of desired mixed materialsmay be employed.

The high energy beam preferably may be an electron beam (e-beam) orlaser beam and may be applied continuously to the powder or pulsed at apredetermined frequency. In some arrangements, the use of a laser ore-beam melting process may preclude the requirement for subsequent heattreatment of the structure fabricated by the additive manufacturingprocess, thereby preserving the initial mechanical properties of thecore or base metal when fused to the fabricated structure. The highenergy beam is emitted from a beam-generating apparatus to heat themetal powder sufficiently to sinter and preferably to at least partiallymelt or melt the metal powder. High energy beam generation equipment formanufacturing such structures may be one of many currently availableincluding the MCP REALIZER, the EOS M270, TRUMPF TRUMAFORM 250, theARCAM EBM S12, and the like. The beam generation equipment may also be acustom-produced laboratory device.

The pore density, pore size and pore size distribution may be controlledfrom one location on the structure to another. It is important to notethat successive powder layers may differ in porosity by varying factorsused for laser scanning powder layers. Additionally, the porosity ofsuccessive layers of powder may be varied by either creating a specifictype of unit cell or manipulating various dimensions of a given unitcell. In some arrangements, the porosity may be a gradient porositythroughout at least a portion of the fabricated structure. The beamgeneration equipment may be programmed to proceed in a random generatedmanner to produce an irregular porous construct but with a defined levelof porosity. Pseudo-random geometries may be formed by applying aperturbation to the vertices of porous geometries when preparing modelbuild structures corresponding to the 3D structure to be fabricated. Inthis manner, the porous geometries may be randomized.

In fabricating a structure corresponding to porous structure 200, afirst layer of metal powder may be deposited and scanned by a highenergy beam to form a first section of the structure corresponding tofirst layer 220 of structure 200. The first section of the structure mayform a base or core of the structure, which as shown may be solid, butin alternative arrangements may be at least partially porous.

Successive layers of the metal powder are then deposited onto theprevious layers of the metal powder and then respectively scanned withthe high energy beam prior to deposition of subsequent layers of themetal powder to form a plurality of struts defining porous geometriescorresponding to the plurality of struts 245 defining porous geometries255 of model build structure 250. In this manner, the fabricatedstructure is formed as a three-dimensional structure corresponding toporous structure 200 in which the struts corresponding to the pluralityof struts 245 intersect at vertices corresponding to nodes 270, 275,which define faces of the porous geometries corresponding to porousgeometries 255. As a result, the porous geometries of the fabricatedstructure corresponding to the porous geometries 255 have faces that atleast partially confront the first section corresponding to first layer220 of structure 200. Each of the fabricated faces is connected to thefirst section by a single joining strut corresponding to single joiningstrut 240 extending to the first section from a vertex of a facepartially confronting the first section and corresponding to one of thenodes 270.

Due to the correspondence of the joining struts of the fabricatedstructure to joining struts 240 of structure 200, the joining struts ofthe fabricated structure all have substantially equal lengths. Thisequivalency eliminates a preferential path for abrasive fluid to flowbetween the porous section of the fabricated structure corresponding tomodel build structure 250 of porous structure 200 and the first sectionof the fabricated structure during polishing the first section. In thismanner, the fatigue strength of the fabricated structure may beincreased.

Although the joining struts are preferably of substantially equallengths to enhance polishing of the first section of the fabricatedstructure, the joining struts of the fabricated structure may correspondto any of joining struts 240, 340, 440 and thus may extend in differentbuild directions.

Referring now to FIG. 8, a computer-generated component file is preparedat block 510. The component file includes a porous CAD volume with aboundary having at least one predefined portion. At block 520, a spacethat includes the porous CAD volume is populated, by a processor, withunit cells that overlap the predefined portion of the boundary. Such aspace may be defined by sets of coordinates, such as Cartesian, polar,or spherical coordinates. At block 530, the unit cells are populated, bya processor, with porous geometries. Within the porous geometries may bea plurality of struts. At least one end of the struts may be attached toa node. As further shown at block 530, at least one of the strutsoverlaps the predefined portion of the boundary. Such a strut has alength, one node outside the porous CAD volume, and one node inside theporous CAD volume. At block 540, any struts entirely outside thepredefined portion of the boundary are removed. In some arrangements,any struts outside the entire boundary are removed. At block 550, thespace is populated, by a processor, with a second strut extending beyondthe boundary from a node for connection with a mating structure. In thismanner, a computer-generated model of a three-dimensional structureconstructed of porous geometries is prepared. At optional block 560, atangible three-dimensional structure having a shape corresponding to thecomputer-generated model may be produced. The shape of thethree-dimensional structure may be in the form of an at least partiallygeometric lattice structure.

Although the invention herein has been described with reference toparticular embodiments, it is to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It is therefore to be understood that numerousmodifications may be made to the illustrative embodiments and that otherarrangements may be devised without departing from the spirit and scopeof the present invention. In this regard, the present inventionencompasses numerous additional features in addition to those specificfeatures set forth in the claims below.

The invention claimed is:
 1. A method of producing a porous structurecomprising the steps of: depositing a first layer of a metal powder ontoa substrate; scanning a portion of the first metal powder layer with ahigh energy beam to form either one or both of a portion of a firstsection of the structure and a portion of a plurality of struts formingporous geometries of a second section of the structure, each of theporous geometries corresponding to respective single unit cells;depositing successive layers of the metal powder onto respectiveprevious metal powder layers; and scanning the successive metal powderlayers with the high energy beam so that the first section, a cellularlayer including the plurality of struts defining the porous geometriesof the second section of the structure, and an interface layer includingattachment struts attaching some of the porous geometries of thecellular layer to the first section are formed, wherein the plurality ofstruts of each of the porous geometries are attached to define vertices,and wherein each vertex of the porous geometries attached to the firstsection by the interface layer is attached to the first section of thestructure by only a single one of the attachment struts.
 2. The methodof claim 1, wherein the high energy beam is an electron beam or a laserbeam.
 3. The method of claim 1, wherein the section of the structure issolid.
 4. The method of claim 1, wherein the attachment struts extend inthe same direction.
 5. The method of claim 1, wherein the attachmentstruts extend along axes extending through a central axis of thesection.
 6. The method of claim 1, wherein the attachment struts havethe same length.
 7. The method of claim 1, wherein the and secondsections are made of a metal powder selected from the group consistingof titanium, titanium alloys, stainless steel, cobalt chrome alloys,tantalum and niobium.
 8. The method of claim 1, wherein the unit cellsare in the form of an octahedron, a dodecahedron, or a tetrahedron. 9.The method of claim 1, further comprising the step of polishing theporous structure with a polishing material.
 10. The method of claim 9,wherein the polishing material is abrasive.
 11. A method of producing aporous structure comprising the steps of: depositing a first layer of ametal powder onto a substrate; scanning a portion of the first metalpowder layer with a high energy beam to form either one or both of aportion of a first section of the structure and a portion of a pluralityof struts forming porous geometries of a second section of thestructure; depositing successive layers of the metal powder ontorespective previous metal powder layers; and scanning the successivemetal powder layers with the high energy beam so that the section, acellular layer including the plurality of struts defining the porousgeometries of the second section of the structure, and an interfacelayer including attachment struts attaching some of the porousgeometries of the cellular layer to the first section are formed,wherein, following the scanning steps, each of the porous geometriescorrespond to respective single unit cells, wherein the plurality ofstruts of each of the porous geometries is attached to define vertices,and wherein each vertex of the porous geometries attached to the sectionby the interface layer is attached to the section of the structure byonly a single one of the attachment struts, the attachment struts beinglonger than the struts of the porous geometries.
 12. The method of claim11, wherein the unit cells are in the form of an octahedron, adodecahedron, or a tetrahedron.
 13. The method of claim 11, wherein thesection of the structure is solid.
 14. A method of producing a porousstructure comprising the steps of: depositing a first layer of a metalpowder onto a substrate; scanning a portion of the first metal powderlayer with a high energy beam to form either one or both of a portion ofa first section of the structure and a portion of a plurality of strutsforming porous geometries of a second section of the structure, each ofthe porous geometries corresponding to respective single unit cells;depositing successive layers of the metal powder onto respectiveprevious metal powder layers; and scanning the successive metal powderlayers with the high energy beam so that the section, a cellular layerincluding the plurality of struts defining the porous geometries of thesecond section of the structure, and an interface layer includingattachment struts attaching some of the porous geometries of thecellular layer to the first section are formed, wherein each of theporous geometries attached to the first section by the interface layerdefine a plurality of faces at least partially confronting the firstsection of the structure, each face being bounded by intersecting strutsat vertices, and wherein less than all of the vertices of each of thefaces of the porous geometries at least partially confronting the firstsection of the structure are connected by a strut to the section of thestructure, each such strut being one of the attachment struts.
 15. Themethod of claim 14, wherein the section of the structure is solid. 16.The method of claim 14, further comprising the step of polishing aninternal portion of the porous structure by directing a polishingmaterial to flow through the interface layer.
 17. The method of claim16, wherein the polishing material is abrasive.
 18. The method of claim1, wherein the interface layer defines pores having a larger pore sizethan all pores defined by the cellular layer.
 19. The method of claim 1,further comprising the step of polishing an internal portion of theporous structure by directing a polishing material to flow through theinterface layer.
 20. The method of claim 11, further comprising the stepof polishing an internal portion of the porous structure by directing apolishing material to flow through the interface layer.